U.S. patent application number 15/772706 was filed with the patent office on 2020-01-09 for diffusive polycarbonate compositions with enhanced flame retardant properties, luminous efficiency and beam angle of optical com.
This patent application is currently assigned to SABIC Global Technologies B.V.. The applicant listed for this patent is SABIC Global Technologies B.V.. Invention is credited to Yingjun CHENG, Yu DING, Guangde HUANG, Huihui LI, Miao SHEN, Haowei TANG, Jian YANG.
Application Number | 20200010669 15/772706 |
Document ID | / |
Family ID | 58661518 |
Filed Date | 2020-01-09 |
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United States Patent
Application |
20200010669 |
Kind Code |
A1 |
SHEN; Miao ; et al. |
January 9, 2020 |
DIFFUSIVE POLYCARBONATE COMPOSITIONS WITH ENHANCED FLAME RETARDANT
PROPERTIES, LUMINOUS EFFICIENCY AND BEAM ANGLE OF OPTICAL
COMPONENTS
Abstract
The disclosure concerns optical components comprising a
polycarbonate-containing composition, the polycarbonate-containing
composition comprising: about 95 wt % to about 99.6 wt %
polycarbonate polymer; about 0.25 wt % to about 1 wt % silicon
resin; about 0.05 wt % to about 0.5 wt % flame retardant; and about
0.1 wt % to about 0.5 wt % styrene-acrylonitrile copolymer coated
polytetrafluoroethylene, wherein the polycarbonate-containing
composition exhibits a VO rating at 0.75 mm as determined by the
UL94 Flammability test, and wherein the total wt % of all
components of the polycarbonate-containing composition does not
exceed 100 wt %.
Inventors: |
SHEN; Miao; (Shanghai,
CN) ; DING; Yu; (Shanghai, CN) ; TANG;
Haowei; (Shanghai, CN) ; YANG; Jian;
(Shanghai, CN) ; CHENG; Yingjun; (Shanghai,
CN) ; HUANG; Guangde; (Shanghai, CN) ; LI;
Huihui; (Shanghai, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SABIC Global Technologies B.V. |
Bergen op Zoom |
|
NL |
|
|
Assignee: |
SABIC Global Technologies
B.V.
Bergen op Zoom
NL
|
Family ID: |
58661518 |
Appl. No.: |
15/772706 |
Filed: |
November 4, 2015 |
PCT Filed: |
November 4, 2015 |
PCT NO: |
PCT/CN2015/093780 |
371 Date: |
May 1, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08K 5/0041 20130101;
C08L 27/18 20130101; B29L 2011/00 20130101; C08L 2203/206 20130101;
C08K 5/5419 20130101; C08L 2207/53 20130101; C08L 25/12 20130101;
C08L 83/04 20130101; C08L 69/00 20130101; B29K 2083/00 20130101;
C08K 5/0066 20130101; C08L 2201/02 20130101; C08G 77/04 20130101;
B29K 2069/00 20130101; B29C 45/0001 20130101; C08L 69/00 20130101;
C08L 83/04 20130101; C08K 5/5419 20130101; C08L 27/18 20130101 |
International
Class: |
C08L 69/00 20060101
C08L069/00; C08L 83/04 20060101 C08L083/04; C08K 5/5419 20060101
C08K005/5419; C08K 5/00 20060101 C08K005/00; B29C 45/00 20060101
B29C045/00; C08L 25/12 20060101 C08L025/12; C08L 27/18 20060101
C08L027/18 |
Claims
1. An optical component comprising a polycarbonate-containing
composition, the polycarbonate-containing composition comprising:
about 95 wt % to about 99.6 wt % polycarbonate polymer; about 0.25
wt % to about 1 wt % silicon resin; about 0.05 wt % to about 0.5 wt
% flame retardant; and about 0.1 wt % to about 0.5 wt %
styrene-acrylonitrile copolymer coated polytetrafluoroethylene,
wherein the polycarbonate-containing composition exhibits a VO
rating at 0.75 mm as determined by the UL94 Flammability test, and
wherein the total wt % of all components of the
polycarbonate-containing composition does not exceed 100 wt %.
2. The optical component of claim 1, wherein at least a portion of
the polycarbonate is a branched polycarbonate.
3. The optical component of claim 2, wherein the branched
polycarbonate is produced from reagents comprising bisphenol A and
1,1,1-tris-(4-hydroxyphenylethane).
4. The optical component of claim 1, wherein the
polycarbonate-containing composition comprises about 10 wt % to
about 90 wt % branched polycarbonate.
5. The optical component of claim 1, additionally comprising one or
more of anti-oxidant, UV stabilizer, and mold release agent.
6. The optical component of claim 1, wherein the optical component
is formed by injection molding.
7. The optical component of claim 1, wherein the
polycarbonate-containing composition exhibits an increased beam
angle versus an analogous composition having no
styrene-acrylonitrile copolymer coated polytetrafluoroethylene.
8. The optical component of claim 1, wherein the
polycarbonate-containing composition exhibits increased luminous
efficiency versus an analogous composition having no
styrene-acrylonitrile copolymer coated polytetrafluoroethylene.
9. The optical component of claim 1, wherein the flame retardant
comprises at least one compound of the formula [(R).sub.2SiO].sub.y
wherein R is a monovalent hydrocarbon or fluorinated hydrocarbon
having from 1 to 18 carbon atoms and y is a number from 3 to
12.
10. The optical component of claim 1, wherein the flame retardant
is octaphenylcyclotetrasiloxane.
11. The optical component of claim 1, additionally comprising one
or more phosphors.
12. The optical component of claim 1 that is a light emitting diode
lamp cover.
13. A light emitting diode light comprising a LED lamp cover of
claim 12.
14. A polycarbonate-containing composition comprising: about 95 wt
% to about 99.6 wt % polycarbonate polymer; about 0.25 wt % to
about 1 wt % silicon resin; about 0.05 wt % to about 0.5 wt % flame
retardant; and about 0.1 wt % to about 0.5 wt %
styrene-acrylonitrile copolymer coated polytetrafluoroethylene;
wherein the total wt % of all components of the
polycarbonate-containing composition does not exceed 100 wt %,
wherein the polycarbonate-containing composition exhibits a VO
rating at 0.75 mm as determined by the UL94 Flammability test, and
wherein the total wt % of all components of the
polycarbonate-containing composition does not exceed 100 wt %.
15. The polycarbonate-containing composition of claim 14, wherein
at least a portion of the polycarbonate is a branched
polycarbonate.
16. The polycarbonate-containing composition of claim 14, wherein
the branched polycarbonate is produced from reagents comprising
bisphenol A and 1,1,1-tris-(4-hydroxyphenylethane).
17. The polycarbonate-containing composition of claim 14, wherein
the polycarbonate-containing composition comprises about 10 to
about 90 wt % branched polycarbonate.
18. The polycarbonate-containing composition of claim 14, wherein
the optical component is formed by injection molding.
19. The polycarbonate-containing composition of claim 14, wherein
the polycarbonate-containing composition exhibits an increased beam
angle versus an analogous composition having no
styrene-acrylonitrile copolymer coated polytetrafluoroethylene.
20. The polycarbonate-containing composition of claim 14, wherein
the polycarbonate-containing composition exhibits increased
luminous efficiency versus an analogous composition having no
styrene-acrylonitrile copolymer coated polytetrafluoroethylene.
Description
TECHNICAL FIELD
[0001] The disclosure concerns polycarbonate-containing
compositions with enhanced flame retardant properties, improved
luminous efficiency and beam angle properties and their use in
optical components such as LED lens covers.
BACKGROUND
[0002] Due to any industry trend of thinner wall design of LED
diffusive components, diffusive engineering plastics which can
maintain UL94 VO flammability at thinner wall is desired. Most fire
retardant (FR) additives are light absorbing and thus sacrifice
luminous efficiency of light components. There is a need in the art
for compositions that overcome this deficiency.
SUMMARY
[0003] The disclosure concerns optical component comprising a
polycarbonate-containing composition, the polycarbonate-containing
composition comprising: about 95 to about 99.6 wt % polycarbonate
polymer; about 0.25 to about 1 wt % silicon resin, about 0.05 to
about 0.5 wt % flame retardant, and about 0.1 to about 0.5 wt %
styrene-acrylonitrile copolymer coated polytetrafluoroethylene,
wherein the total wt % of all components of the
polycarbonate-containing composition does not exceed 100 wt %.
[0004] Some preferred optical components are LED lamp covers.
[0005] Some preferred flame retardants comprise at least one
compound of the formula
[(R).sub.2SiO].sub.y
wherein R is a monovalent hydrocarbon or fluorinated hydrocarbon
having from 1 to 18 carbon atoms and y is a number from 3 to 12. In
some embodiments, the flame retardant is
octaphenylcyclotetrasiloxane.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0006] The disclosure concerns optical component comprising a
polycarbonate-containing composition, the polycarbonate-containing
composition comprising: about 95 to about 99.6 wt % polycarbonate
polymer; about 0.25 to about 1 wt % silicon resin, about 0.05 to
about 0.5 wt % flame retardant, and about 0.1 to about 0.5 wt %
styrene-acrylonitrile copolymer coated polytetrafluoroethylene,
wherein the total wt % of all components of the
polycarbonate-containing composition does not exceed 100 wt %.
Polycarbonate (PC)
[0007] Composition disclosed herein comprises about 95 wt % to
about 99.6 wt % polycarbonate polymer based on the weight of the
composition. In some embodiments, the amount of polycarbonate is
about 97 wt % to about 99 wt %. In certain embodiments, at least a
portion of the polycarbonate is a branched polycarbonate; about 10
wt % to about 90 wt % branched polycarbonate in some compositions.
In other compositions, the amount of branched polycarbonate is
about 20 wt % to about 80 wt % or about 30 wt % to about 70 wt % or
about 40 wt % to about 60 wt %, or about 50 wt %, based on the
weight of the composition.
[0008] Some branched polycarbonate is produced from reagents
comprising bisphenol A and 1,1,1-tris-(4-hydroxyphenylethane).
[0009] The terms "polycarbonate" or "polycarbonates" as used herein
includes copolycarbonates, homopolycarbonates and (co)polyester
carbonates. PC polymers are available commercially from SABIC.
[0010] The term polycarbonate can be further defined as
compositions have repeating structural units of the formula
(1):
##STR00001##
in which at least 60 percent of the total number of R.sup.1 groups
are aromatic organic radicals and the balance thereof are
aliphatic, alicyclic, or aromatic radicals. In a further aspect,
each R1 is an aromatic organic radical and, more preferably, a
radical of the formula (2):
-A.sup.1-Y1-A.sup.2- (2),
wherein each of A.sup.1 and A.sup.2 is a monocyclic divalent aryl
radical and Y.sup.1 is a bridging radical having one or two atoms
that separate A.sup.1 from A.sup.2. In various aspects, one atom
separates A.sup.1 from A.sup.2. For example, radicals of this type
include, but are not limited to, radicals such as --O--, --S--,
--S(O)--, --S(O.sub.2)--, --C(O)--, methylene,
cyclohexyl-methylene, 2-[2.2.1]-bicycloheptylidene, ethylidene,
isopropylidene, neopentylidene, cyclohexylidene,
cyclopentadecylidene, cyclododecylidene, and adamantylidene. The
bridging radical Y1 is preferably a hydrocarbon group or a
saturated hydrocarbon group such as methylene, cyclohexylidene, or
isopropylidene. Polycarbonate materials include materials disclosed
and described in U.S. Pat. No. 7,786,246, which is hereby
incorporated by reference in its entirety for the specific purpose
of disclosing various polycarbonate compositions and methods for
manufacture of the same.
[0011] Generally polycarbonates can have a weight average molecular
weight (Mw), of greater than about 5,000 g/mol based on PS
standards. In one aspect, the polycarbonates can have an Mw of
greater than or equal to about 20,000 g/mol, based on PS standards.
In another aspect, the polycarbonates have an Mw based on PS
standards of about 20,000 to 100,000 g/mol, including for example
30,000 g/mol, 40,000 g/mol, 50,000 g/mol, 60,000 g/mol, 70,000
g/mol, 80,000 g/mol, or 90,000 g/mol. In still further aspects, the
polycarbonates have an Mw based on PS standards of about 22,000 to
about 50,000 g/mol. In still further aspects, the polycarbonates
have an Mw based on PS standards of about 25,000 to 40,000
g/mol.
[0012] In certain embodiments, the polycarbonate may comprise two
or more polycarbonate compositions that differ in molecular weight
and/or compositional variations.
[0013] Certain polycarbonates are sold under the trade name
LEXAN.TM. by SABIC Innovative Plastics of Pittsfield, Mass.
Silicon Resin
[0014] Compositions disclosed herein comprise about 0.25 to about 1
wt % silicon resin based on the weight of the composition. Certain
compositions comprise 0.4 to about 0.8 wt % of silicon resin.
[0015] Useful silicones include polymerized siloxanes Examples
include silicone oil and octaphenylcyclotetrasiloxane.
Flame Retardant
[0016] Compositions of the disclosure comprise about 0.05 to about
0.5 wt % flame retardant based on the weight of the composition. In
some embodiments, about 0.1 wt % to about 0.4 wt % of flame
retardant is present in the composition.
[0017] Certain flame retardant comprise at least one compound of
the formula
[(R).sub.2SiO].sub.y
wherein R is a monovalent hydrocarbon or fluorinated hydrocarbon
having from 1 to 18 carbon atoms and y is a number from 3 to 12.
One preferred flame retardant is octaphenylcyclotetrasiloxane.
Styrene-Acrylonitrile Copolymer Coated Polytetrafluoroethylene
[0018] The compositions of the disclosure comprise about 0.1 to
about 0.5 wt % styrene-acrylonitrile copolymer coated
polytetrafluoroethylene. Encapsulated fluoropolymers can be made by
polymerizing the encapsulating polymer in the presence of the
fluoropolymer, for example an aqueous dispersion. TSAN can provide
significant advantages over PTFE, in that TSAN can be more readily
dispersed in the composition. An exemplary TSAN can comprise 50 wt
% PTFE and 50 wt % SAN, based on the total weight of the
encapsulated fluoropolymer. The SAN can comprise, for example, 75
wt % styrene and 25 wt % acrylonitrile based on the total weight of
the copolymer. Alternatively, the fluoropolymer can be pre-blended
in some manner with a second polymer, such as for, example, an
aromatic polycarbonate or SAN to form an agglomerated material for
use as an anti-drip agent. Either method can be used to produce an
encapsulated fluoropolymer.
Phosphors
[0019] Phosphors, also known as "luminescent conversion materials",
can be compounded into the polycarbonate compositions disclosed
herein. In one aspect, the phosphor material is configured to
convert light emitted by a light source such as a light-emitting
diode (LED) into light having a different wavelength. For example,
the phosphor material may be configured to convert the light
emitted by an LED to a higher or lower wavelength as needed.
[0020] Phosphors are typically inorganic compounds. Examples of
phosphor materials include yttrium aluminum garnet (YAG) doped with
rare earth elements, terbium aluminum garnet doped with rare earth
elements, silicate (BOSE) doped with rare earth elements; nitrido
silicates doped with rare earth elements; nitride orthosilicate
doped with rare earth elements, and oxonitridoaluminosilicates
doped with rare earth elements. Quantum dots comprising inorganic
materials, usually cadmium based phosphorescent compounds may also
be used to form opaque and translucent polycarbonates.
[0021] The phosphor material is typically in the form of a solid
powder. The phosphor material may include red-emitting phosphors,
green-emitting phosphors, and yellow-emitting phosphors. In one
aspect, the phosphor material may comprise a mixture of two or more
of red-emitting phosphor, green-emitting phosphor and
yellow-emitting phosphor.
[0022] In some embodiments, the phosphor material can comprise Si,
Sr, Ba, Ca, Eu, Y, Tb, B, N, Se, Ti, or a combination comprising at
least one of the foregoing. The phosphor can comprise greater than
0 ppm of a first material comprising Si, Sr, Ba, Ca, Eu, or a
combination comprising at least one of the foregoing; and less than
50 ppm of a second material comprising Al, Co, Fe, Mg, Mo, Na, Ni,
Pd, P, Rh, Sb, Ti, Zr, or a combination comprising at least one of
the foregoing based on the total weight of the phosphor. The
phosphor can comprise greater than 0 ppm of a first material
consisting of Si, Sr, Ba, Ca, Eu, or a combination comprising at
least one of the foregoing; and less than 50 ppm of a second
material consisting of Al, Co, Fe, Mg, Mo, Na, Ni, Pd, P, Rh, Sb,
Ti, Zr, or a combination comprising at least one of the foregoing
based on the total weight of the phosphor.
[0023] The phosphor can comprise a yttrium aluminum garnet, a
terbium aluminum garnet, a boron silicate; a nitrido silicates; a
nitride orthosilicate, a oxonitrido aluminosilicates, or a
combination comprising at least one of the foregoing. The phosphor
can comprise a strontium silicate yellow phosphor, a yttrium
aluminum garnet, a terbium aluminum garnet, a silicate phosphor, a
nitride phosphor; a nitrido silicate, a nitride orthosilicate, an
oxonitridoaluminosilicate, an alumino nitrido silicate, a
nitridoaluminate, a lutetium aluminum garnet, or a combination
comprising at least one of the foregoing. The alumino nitrido
silicate can comprise CaAlSiN.sub.3:Eu that can be free of Sr
(i.e., can comprise 0 wt % of Sr), (Sr,Ca)AlSiN.sub.3:Eu), or a
combination comprising at least one of the foregoing.
[0024] The phosphor can comprise a lutetium aluminum garnet
containing at least one alkaline earth metal and at least one
halogen dope with a rare earth element.
[0025] The phosphor can comprise a rare earth element,
cerium.sup.3+ or europium.sup.2+ for example, as a dopant.
[0026] In certain embodiments, the phosphor can comprise
green-emitting lutetium aluminate phosphor comprising lutetium,
cerium, at least one alkaline earth metal, aluminum, oxygen, and at
least one halogen.
[0027] Some phosphor materials can convert some of the blue light
from a blue LED to yellow light, and the overall combination of
available light is perceived as white light to an observer.
[0028] The phosphor can comprise a phosphor having formula:
(A.sup.3).sub.2SiO.sub.4:Eu.sup.2+D.sup.1, where A.sup.3 is a
divalent metal selected from Sr, Ca, Ba, Mg, Zn, Cd, and
combinations comprising at least one of the foregoing, and D.sup.1
is a dopant selected from F, Cl, Br, I, P, S or N, and optionally
combinations comprising at least one of the foregoing.
[0029] The phosphor can comprise a phosphor having formula:
(A.sup.4).sub.2SiO.sub.4:Eu.sup.2+D.sup.2 with an optional dopant
selected from Al, Co, Fe, Mg, Mo, Na, Ni, Pd, P, Rh, Sb, Ti or Zr,
and optionally combinations comprising at least one of the
foregoing, wherein A.sup.4 is selected from Sr, Ba, Ca, and
combinations comprising at least one of the foregoing.
[0030] The phosphor can comprise a phosphor having formula:
(YA.sup.5).sub.3(AlB).sub.5(OD.sup.3).sub.12:Ce.sup.3+, where
A.sup.5 is a trivalent metal selected from Gd, Tb, La, Sm, or a
divalent metal ion such as Sr, Ca, Ba, Mg, Zn, Cd, and combinations
comprising at least one of the foregoing; B is selected from Si, B,
P, and Ga, and optionally combinations comprising at least one of
the foregoing; and D.sup.3 is a dopant selected from F, Cl, Br, I,
P, S or N, and optionally combinations comprising at least one of
the foregoing. Other possible yellow material(s) include:
Y.sub.3Al.sub.5O.sub.12:Ce; Tb.sub.3-xRE.sub.xAl.sub.5O.sub.12:Ce
(TAG), wherein RE=Y, Gd, La, Lu;
Sr.sub.2-x-yBa.sub.xCa.sub.ySiO.sub.4:Eu;
Sr.sub.3-xSiO.sub.5:Eu.sup.2+.sub.x, wherein 0<x.ltoreq.1.
Possible yellow/green material(s) include:
(Sr,Ca,Ba)(Al,Ga).sub.2S.sub.4:Eu.sup.2+;
Ba.sub.2(Mg,Zn)Si.sub.2O.sub.7:Eu.sup.2+;
Gd.sub.0.46Sr.sub.0.31Al.sub.1.23O.sub.xF.sub.1.38:Eu.sup.2+.sub.0.06;
(Ba.sub.1-x-ySr.sub.xCa.sub.y)SiO.sub.4:Eu; and
Ba.sub.2SiO.sub.4:Eu.sup.2+.
[0031] The phosphor material can comprise a phosphor having
formula: (YGd).sub.3Al.sub.5O.sub.12:Ce3+ or
Y.sub.3Al.sub.5(OD.sup.3).sub.12:Ce.sup.3+.
[0032] The phosphor can comprise an orange-red silicate-based
phosphor(s) having formula: (SrM1).sub.3Si(OD.sup.4).sub.5:Eu,
where M1 is selected from Ba, Ca, Mg, Zn, and combinations
comprising at least one of the foregoing; and D.sup.4 is selected
from F, Cl, S, and N, and optionally combinations comprising at
least one of the foregoing; phosphor(s); a Eu.sup.2+ doped and or
Dy.sup.3+ phosphor(s) having formula: M.sub.3MgSi.sub.2O.sub.8,
wherein M is selected from Ca, Sr, Ba, and combinations comprising
at least one of the foregoing.
[0033] The phosphor can comprise a red silicon nitride based
Eu.sup.2+ doped phosphor(s) having a formula:
(SrM.sub.2).sub.2Si.sub.5N.sub.8, where M2 is selected from Ca, Mg,
and Zn and combination comprising at least one of the foregoing.
Other nitridosilicates, oxonitridosilicates,
oxonitridoaluminosilicates examples include:
Ba.sub.2SiN.sub.8:Eu.sup.2+; alpha-SiAlON:Re (Re=Eu.sup.2+,
Ce.sup.3+, Yb.sup.2+, Tb.sup.3+, Pr.sup.3+, Sm.sup.3+, and
optionally combinations comprising at least one of the foregoing);
Beta-SiAlON:Eu.sup.2+; Sr.sub.2Si.sub.5N.sub.8:Eu.sup.2+,Ce.sup.3+;
a rare earth doped red sulfide based phosphor (such as (SrM3)S,
where M3 is selected from Ca, Ba, and Mg, and optionally
combinations comprising at least one of the foregoing);
Sr.sub.xCa.sub.1-xS:Eu,Y, wherein Y is a halide;
CaSiAlN.sub.3:Eu.sup.2+; Sr.sub.2-yCa.sub.ySiO.sub.4:Eu;
Lu.sub.2O.sub.3:Eu.sup.3+;
(Sr.sub.2-xLa.sub.x)(Ce.sub.1-xEu.sub.x)O.sub.4;
Sr.sub.2Ce.sub.1-xEu.sub.xO.sub.4; Sr.sub.2-xEu.sub.xCeO.sub.4;
SrTiO.sub.3:Pr.sup.3+,Ga.sup.3+; CaAlSiN.sub.3:Eu.sup.2+;
Sr.sub.2Si.sub.5N.sub.8:Eu.sup.2+, or a combination comprising at
least one of the foregoing.
[0034] The phosphor can comprise a blue phosphor such as
BaMgAl.sub.10O.sub.17:Eu.sup.2+.
[0035] The phosphor can comprise a green sulfide based phosphor
such as (SrM3)(GaM4).sub.2S.sub.4:Eu; where M3 is set forth above,
and M4 is selected from Al and In.
[0036] The phosphor can comprise
Tb.sub.3-xRE.sup.1.sub.xO.sub.12:Ce(TAG), wherein RE.sup.1 is
selected from Y, Gd, La, Lu, and combinations comprising at least
one of the foregoing; yttrium aluminum garnet (YAG) doped with
cerium (e.g., (Y,Gd).sub.3Al.sub.5O.sub.12:Ce.sup.3+; YAG:Ce);
terbium aluminum garnet doped with cerium (TAG:Ce); a silicate
phosphor material (e.g., (Sr).sub.2SiO.sub.4:Eu,
(Ba).sub.2SiO.sub.4:Eu, (Ca).sub.2SiO.sub.4:Eu); a nitride phosphor
material (e.g., doped with cerium and/or europium); a nitrido
silicate (e.g., LaSi.sub.3N.sub.5:Eu.sup.2+, O.sup.2- or
Ba.sub.2Si.sub.5N.sub.8:Eu.sup.2+); a nitride orthosilicate (e.g.,
such as disclosed in DE 10 2006 016 548 A1); or combinations
comprising at least one of the foregoing. The coated YAG:Ce based
phosphor material(s) can be synthetic aluminum garnets, with garnet
structure A.sub.3.sup.3+B.sub.5.sup.3+O.sub.12.sup.2- (containing
Al.sub.5O.sub.12.sup.9- and A is a trivalent element such as
Y.sup.3+). The aluminum garnet can be synthetically prepared in
such a manner (annealing) as to impart a short-lived luminescence
lifetime lasting less than 10.sup.-4 s. Other possible green
phosphor material(s) include: SrGa2S.sub.4:Eu,
Sr.sub.2-yBaySiO.sub.4:Eu, SrSiO.sub.2N.sub.2:Eu, and
Ca.sub.3Si.sub.2O.sub.4N.sub.2:Eu.sup.2+.
[0037] The phosphor can comprise a yellow phosphor(s) (such as
(Y,Gd).sub.3Al.sub.5O.sub.12:Ce3+ or (Sr,Ba,Ca).sub.2SiO.sub.4:Eu)
and a red phosphor material(s) (such as (Sr,Ca)AlSiN.sub.3:Eu),
e.g., to produce a warm white light. The phosphor material(s)
comprise combinations of a green aluminate (GAL) and a red phosphor
material(s) (e.g., to produce white light from the RGB of blue led,
green light, and red light). Green aluminate and a red nitride
phosphor can be used alone or combined to generate white light when
exposed to blue LED light. The red nitride phosphor material can
contain ions to promote quantum efficiency. The phosphor material
can comprise a combination of a semiconductor nanocrystals of
cadmium sulfide mixed with manganese; and/or a
La.sub.3Si.sub.6N.sub.11:Ce.sup.3+. A YAG:Ce phosphor material or a
BOSE (boron ortho-silicate) phosphor, for example, can be utilized
to convert the blue light to yellow. A reddish AlInGaP LED can be
included to pull yellow light from the phosphor to the black body
curve.
[0038] The phosphor can comprise a down converting agent (such as
(py).sub.24Nd.sub.28F.sub.68(SePh).sub.16, where py is pyridine),
an up converting agent (such as 0.2 wt % Ti.sup.2+:NaCl and 0.1 wt
% Ti.sup.2+:MgCl.sub.2), or a combination comprising one or both of
the foregoing. The phosphor can comprise an organic dye (such as
Rhodamine 6G, Lumogen.TM. 083), a quantum dot, a rare earth
complex, or a combination comprising one or more of the foregoing.
The organic dye molecules can be attached to a polymer backbone or
can be dispersed in the radiation emitting layer. The phosphor can
comprise a pyrazine type compound having a substituted amino and/or
cyano group, pteridine compounds such as benzopteridine
derivatives, perylene type compounds, anthraquinone type compounds,
thioindigo type compounds, naphthalene type compounds, xanthene
type compounds, or a combination comprising one or more of the
foregoing. The phosphor can comprise pyrrolopyrrole cyanine (PPCy),
a bis(PPCy) dye, an acceptor-substituted squaraine, or a
combination comprising one or more of the foregoing. The
pyrrolopyrrole cyanine can comprise BF.sub.2-PPCy, BPh.sub.2-PPCy,
bis(BF.sub.2-PPCy), bis(BPh.sub.2-PPCy), or a combination
comprising one or more of the foregoing. The phosphor can comprise
a lanthanide-based compound such as a lanthanide chelate. The
phosphor can comprise a chalcogenide-bound lanthanide. The phosphor
can comprise a transition metal ion such as one or both of
Ti.sup.2+-doped NaCl and Ti.sup.2+-doped MgCl.sub.2.
[0039] The phosphor can comprise a combination comprising at least
one of the foregoing phosphors.
[0040] The phosphor can be free of an aluminum spinel, wherein a
spinel has the structure A.sup.2+B.sub.2.sup.3+O.sub.4.sup.2-
(Al.sub.2O.sub.4.sup.2- and A is a divalent alkaline earth element
such as Ca.sup.2+, Sr.sup.2+, and Ba.sup.2+).
[0041] The polymer composition can comprise 0.5 to 20 wt %, or 1 to
10 wt %, or 3 to 8 wt % of the phosphor based on the total weight
of the composition. The polymer composition can comprise 0.1 to 40
parts by weight (pbw), or 4 to 20 pbw of the phosphor based on 100
pbw of polymer.
[0042] The phosphor can have a median particle size of 10
nanometers (nm) to 100 micrometers (.mu.m), as determined by laser
diffraction. The median particle size is sometimes indicated as
D.sub.50-value. The median particle size can be 1 to 30
micrometers, or 5 to 25 micrometers. Examples of median particle
sizes include 1 to 5 micrometers, or 5 to 10 micrometers, or 11 to
15 micrometers, or 16 to 20 micrometers, or 21 to 25 micrometers,
or 26 to 30 micrometers, or 31 to 100 micrometers.
[0043] The phosphor can be sized such that it does not reduce the
transparency of the radiation emitting layer, for example, the
phosphor can be one that does not scatter visible light, or light
with a wavelength of 390 to 700 nanometers (nm). The phosphor can
have a longest average dimension of less than or equal to 300 nm,
or less than or equal to 100 nm, or less than or equal to 40 nm, or
1 to 35 nm.
[0044] The phosphor can be coated (e.g., result of applying a
material to the surface of the phosphor, wherein the coating is on
the surface and/or chemically interacts with the surface).
Radiometric values (such as radiant power, radiant intensity,
irradiance, and radiance) and corresponding photometric values
(such as total luminance flux, luminous intensity, illuminance,
luminance), luminance efficacy (in lumens per watt (lm/W)), color
rendering index, color quality scale (CQS), correlated color
temperature, and chromaticity, can improve compared to the uncoated
phosphor(s) when added to a polymer material such as
polycarbonate.
[0045] The phosphor can be coated with a silicone oil and/or a
layer of amorphous silica. Some examples of silicone oils include,
but are not limited to: hydrogen-alkyl siloxane oil; polydialkyl
siloxane oil; polydimethyl siloxane codiphenyl siloxane, dihydroxy
terminated (such as Gelest PDS 1615 commercially available from
Gelest, Inc.); as well as combinations comprising at least one of
the foregoing. Such silicone oils are considered coatings where the
phosphor is first treated with the silicone oil(s) prior to
addition to a matrix or binder (collectively referred to as
matrix), such as polycarbonate. The coating itself, is neither the
binder nor the matrix that contains the phosphor to hold in place
for exposure to blue LED radiation. Additionally, the coating does
not require a curing method.
[0046] The phosphor can be coated with silicone oil e.g., by a
method such as spraying the silicon oil. For example, the phosphor
can be coated by spraying of the silicone oil in a fluidized bed
reactor. The total amount of silicone oil can be 0.05 to 10 wt %
with respect to the phosphor, or 0.1 to 10 wt %, or 0.5 to 5 wt %,
based upon the total weight of the phosphor. When two silicone
coatings are used, such as polymethylhydrosiloxane and
polydimethylsiloxane, the total amount does not change, and the
split ratio between the two oils can be 1:99 to 99:1. The first
coating can represent at least about 50 wt % of the total silicone
oil content.
[0047] Some examples of oils include polymethylhydrosiloxane (for
example, DF 1040 commercially available from Momentive Performance
Materials) and polydimethyl siloxane (e.g., DF581 commercially
available from Momentive Performance Materials). Other examples
include diphenyl siloxane, e.g., silanol terminated oils such as
silanol terminated diphenylsiloxane (e.g., PDS-1615 commercially
available from Gelest, Inc., Morrisville, Pa.). The polymer
composition can comprise up to 4 parts per hundred (pph) by weight,
or 0.1 to 0.5 (e.g., 0.2) pph by weight of a pigment (e.g., Gelest
PDS-1615). Other possible silanol terminated siloxanes include
PDS-0338 and PDS-9931 also commercially available from Gelest, Inc.
The polymer composition can comprise less than or equal to 20 pbw
of coated phosphor to 100 pbw of polymer.
[0048] Additional phosphors include Quantum dots including
semiconductor nanocrystal. Such materials include Cd-based,
Cd-based core/shell passivated with ZnS shell, alloyed quantum dots
such as CdSeTe, InP, InP/ZnS core/shell and ZnSe/InP/ZnS
core/shell/shell, CuInS2, ZnS--CuInS2 alloy with ZnS shell, and
CuInS.sub.2/ZnS core/shell materials. Yet other phosphors are
manganese based phosphors such as K.sub.2SiF.sub.6:Mn.sup.4+;
K.sub.2(TaF.sub.7):Mn.sup.4+; KMgBO.sub.3:Mn.sup.2+. Phosphors also
include narrow band red phosphor: Sr[LiAl.sub.3N.sub.4]:Eu.sup.2+.
A narrow-band phosphor, FWHM 25-35 nm, preferably <30 nm,
absorbs 450 nm light, relative quantum yield greater than or equal
to 90% (at least 150.degree. C./25.degree. C.), prefer greater of
equal to 95%, and quantum yield loss to thermal quenching less than
10% at 150.degree. C. Phosphors include carbidonitride- and
oxycarbidonitride-based phosphors. Other phosphors may be of the
formula CaAlSiN.sub.3:Eu.
Other Additives
[0049] Other optional additives include one or more of
anti-oxidant, UV stabilizer, plasticizers, lubricants and mold
release agent. The compositions can include various additives
ordinarily incorporated into polymer compositions of this type,
with the proviso that the additive(s) are selected so as to not
significantly adversely affect the desired properties of the
thermoplastic composition (good compatibility for example). Such
additives can be mixed at a suitable time during the mixing of the
components for forming the composition.
[0050] There is considerable overlap among plasticizers,
lubricants, and mold release agents, which include, for example,
glycerol tristearate (GTS), phthalic acid esters (e.g.,
octyl-4,5-epoxy-hexahydrophthalate),
tris-(octoxycarbonylethyl)isocyanurate, tristearin, di- or
polyfunctional aromatic phosphates (e.g., resorcinol tetraphenyl
diphosphate (RDP), the bis(diphenyl) phosphate of hydroquinone and
the bis(diphenyl) phosphate of bisphenol A); poly-alpha-olefins;
epoxidized soybean oil; silicones, including silicone oils (e.g.,
poly(dimethyl diphenyl siloxanes); esters, for example, fatty acid
esters (e.g., alkyl stearyl esters, such as, methyl stearate,
stearyl stearate, and the like), waxes (e.g., beeswax, montan wax,
paraffin wax, or the like), or combinations comprising at least one
of the foregoing plasticizers, lubricants, and mold release agents.
These are generally used in amounts of 0.01 to 5 wt %, based on the
total weight of the polymer in the composition.
[0051] Light stabilizers, in particular ultraviolet light (UV)
absorbing additives, also referred to as UV stabilizers, include
hydroxybenzophenones (e.g., 2-hydroxy-4-n-octoxy benzophenone),
hydroxybenzotriazines, cyanoacrylates, oxanilides, benzoxazinones
(e.g., 2,2'-(1,4-phenylene)bis(4H-3,1-benzoxazin-4-one,
commercially available under the trade name CYASORB UV-3638 from
Cytec), aryl salicylates, hydroxybenzotriazoles (e.g.,
2-(2-hydroxy-5-methylphenyl)benzotriazole,
2-(2-hydroxy-5-tert-octylphenyl)benzotriazole, and
2-(2H-benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)-phenol,
commercially available under the trade name CYASORB 5411 from
Cytec) or combinations comprising at least one of the foregoing
light stabilizers. The UV stabilizers can be present in an amount
of 0.01 to 1 wt %, specifically, 0.1 to 0.5 wt %, and more
specifically, 0.15 to 0.4 wt %, based upon the total weight of
polymer in the composition.
[0052] Antioxidant additives include organophosphites such as
tris(nonyl phenyl)phosphite, tris(2,4-di-t-butylphenyl)phosphite,
bis(2,4-di-t-butylphenyl)pentaerythritol diphosphite, distearyl
pentaerythritol diphosphite; alkylated monophenols or polyphenols;
alkylated reaction products of polyphenols with dienes, such as
tetrakis[methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)]
methane; butylated reaction products of para-cresol or
dicyclopentadiene; alkylated hydroquinones; hydroxylated
thiodiphenyl ethers; alkylidene-bisphenols; benzyl compounds;
esters of beta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid
with monohydric or polyhydric alcohols; esters of
beta-(5-tert-butyl-4-hydroxy-3-methylphenyl)-propionic acid with
monohydric or polyhydric alcohols; esters of thioalkyl or thioaryl
compounds such as distearylthiopropionate, dilaurylthiopropionate,
ditridecylthiodipropionate,
octadecyl-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate,
pentaerythrityl-tetrakis[3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate;
amides of beta-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionic acid,
or combinations comprising at least one of the foregoing
antioxidants. Antioxidants are used in amounts of 0.01 to 0.1 parts
by weight, based on 100 parts by weight of the total
composition.
Optical Component
[0053] Optical components can be formed by conventional means known
in the art. In some embodiments, the optical component is formed by
conventional molding techniques. In one embodiment, the molding
techniques include, without limitation, injection molding, blow
molding, and compression molding. Molded articles may also be
prepared from a compositional blend described herein. Such blends
may be prepared using extrusion methods may be molded using
conventional techniques. In certain embodiment, the molded article
is prepared using injection molding.
[0054] Some optical components comprise a polycarbonate-containing
composition that exhibits a VO rating at 0.75 mm as determined by
the UL94 Flammability test. Certain optical components comprise a
polycarbonate-containing composition that exhibits one or both of
(i) an increased beam angle versus an analogous composition having
no styrene-acrylonitrile copolymer coated polytetrafluoroethylene
and (ii) increased luminous efficiency versus an analogous
composition having no styrene-acrylonitrile copolymer coated
polytetrafluoroethylene.
[0055] Optical components include LED lamp covers.
Examples
[0056] The following examples are intended to be illustrative and
not limiting.
[0057] LUX9616G (Lexan from SABIC) was selected as the control. It
is a 1.5 mm V0 PC consisting of polycarbonate (THPE based branched
PC from high purity BPA2, SABIC), polycarbonate (high purity PC
175, SABIC), polycarbonate (high purity PC 105, SABIC), potassium
perfluorobutane sulfonate (Bayowet C4, Lanxess),
octaphenylcyclotetrasiloxane (SX-12-B, Shin-Etsu), pentaerythritol
tetrastearate (Alkanox 240, Chemtura), tris(2,4-ditert-butylphenyl)
phosphite (Alkanox 240, BASF), Cyasorb UV 3638 (Cyasorb UV-3638F,
Cytec), Octadecyl3(3,5ditertbutyl4hydroxyphenyl)propionate
(hindered phenol anti-oxidant) (IRGANOX 1076, Ciba). Polycarbonate
was used as base resin, Cyasorb UV 3638 worked as UV stabilizer,
tris(2,4-ditertbutylphenyl) phosphite and
Octadecyl3(3,5ditertbutyl4hydroxyphenyl)propionate (hindered phenol
anti-oxidant) were antioxidants, pentaerythritol tetrastearate was
employed as mold release agent, potassium perfluorobutane,
sulfonate and octaphenylcyclotetrasiloxane were FR additives. TSAN
was incorporated into the composite to further improve FR
performance.
[0058] TSAN loading from 0 to 0.25 pph were screened in the
presence of 0.5 pph silicone resin beads as diffuser (Tospearl 120
from Momentive). Additionally, composites with 0.2 pph TSAN were
compared with non-TSAN composites LUX9616G at several diffusion
levels.
[0059] For FR comparison, 1.0 mm and 0.75 mm UL bars were molded
and tested following UL94 standard. For optical comparison, A60
bulbs with 1.0/0.8 mm wall thickness were molded for luminous
efficiency and beam angle.
[0060] The composites were prepared from twin screw extruder with
detailed compounding profile presented in Table 1.
TABLE-US-00001 TABLE 1 Compounding profile Parameters Unit
Polycarbonate Composites Compounder Type NONE TEM-37BS Barrel Size
mm 1500 Screw Design NONE L-3-2 Die mm 3 Feed (Zone 0) Temp
.degree. C. 50 Zone 1 Temp .degree. C. 50 Zone 2 Temp .degree. C.
100 Zone 3 Temp .degree. C. 270 Zone 4 Temp .degree. C. 270 Zone 5
Temp .degree. C. 270 Zone 6 Temp .degree. C. 270 Zone 7 Temp
.degree. C. 270 Zone 8 Temp .degree. C. 270 Zone 9 Temp .degree. C.
270 Zone 10 Temp .degree. C. 270 Zone 11 Temp .degree. C. 270 Die
Temp .degree. C. 270 Screw speed rpm 400 Throughput kg/hr 40
[0061] The UL bar molding profile is shown in Table 2.
TABLE-US-00002 TABLE 2 Molding profile Molding Machine NONE Nestal
Mold Type (insert) NONE UL bar Cnd: Pre-drying time Hour 3 Cnd:
Pre-drying temp .degree. C. 120 Hopper temp .degree. C. 50 Zone 1
temp .degree. C. 270-280 Zone 2 temp .degree. C. 275-285 Zone 3
temp .degree. C. 280-290 Nozzle temp .degree. C. 275-285 Mold temp
.degree. C. 50-85 Screw speed rpm 100 Back pressure kgf/cm.sup.2
50-80 Cooling time s 15 Injection speed (mm/s) mm/s 30-150 Holding
pressure kgf/cm.sup.2 600-800 Max. Injection Pressure kgf/cm.sup.2
1000-1200
[0062] Table 3 presents FR and optical performance of composites
with TSAN loading from 0 to 0.25 pph in the presence of 0.5 pph
silicone resin beads.
TABLE-US-00003 TABLE 3 TSAN loading screening Item Item Code Item
Description Unit C1 E1 E2 E3 PC 91982 THPE based branched pph 66 66
66 66 PC PC 91761 High purity PC 175 pph 32.045 32.045 32.045
32.045 PC 91061 High Purity PC pph 1 1 1 1 Additive F4455 Potassium
pph 0.08 0.08 0.08 0.08 perfluorobutane, Additive F491
Octaphenylcyclotetrasilo pph 0.35 0.35 0.35 0.35 Additive F538
Pentaerythritol pph 0.35 0.35 0.35 0.35 Additive F542 Phosphite
stabilizer pph 0.06 0.06 0.06 0.06 Additive F6525 Cyasorb UV-3638
pph 0.095 0.095 0.095 0.095 Additive F527 Hindered phenol anti- pph
0.02 0.02 0.02 0.02 oxidant Diffuser R010722 Tospearl 120 pph 0.5
0.5 0.5 0.5 TSAN F449 SAN encapsulated PTFE pph 0 0.1 0.2 0.25
Typical Property Test Method Test Description Unit C1 E1 E3 E4 MFR
ASTM D 1238 300.degree. C./1.2 kg/300 s g/10 min 7.49 7.28 8.6 6.89
Luminous Integrating -- % 83.8 93.2 92.7 93.2 Beam Angle
Goniophotomet -- degree 183.2 194.4 200.0 208.2 No. of burning UL94
-- -- 1 2 0 0 drops p(FTP)V0 UL94 -- -- 0.24 0.19 0.70 0.69 FOT 5 s
41.5 55.2 35.0 39.1
[0063] It is observed that with the increase of TSAN loading, 1 mm
% T of flat color chip drops. This is in accordance with general
knowledge. TSAN increases scattering when incorporated into PC,
which leads to less transmitted light.
[0064] With 0.2 pph TSAN, FR performance is significantly improved.
The composites contain 0.2+ pph TSAN can pass 1.0 mm VO test.
[0065] The addition of 0.1 pph TSAN significantly improves luminous
efficiency. However, when the loading is further elevated from 0.1
to 0.25 pph, there is no further improvement in luminous
efficiency.
[0066] Inclusion of TSAN increases beam angle.
[0067] Table 4 presents optical evaluation of 0.2 pph TSAN in
different diffusion levels.
TABLE-US-00004 TABLE 4 Item Item Code Item Description Unit C2 E4
C3 E5 C4 E6 PC 91982 THPE based branched PC pph 66 66 66 66 66 66
from high purity BPA2 PC 91761 High purity PC 175 pph 32.045 32.045
32.045 32.045 32.045 32.045 PC 91061 High Purity PC pph 1 1 1 1 1 1
Additive F4455 Potassium pph 0.08 0.08 0.08 0.08 0.08 0.08
perfluorobutane, sulfonate Additive F491
Octaphenylcyclotetrasiloxane pph 0.35 0.35 0.35 0.35 0.35 0.35
Additive F538 Pentaerythritol tetrastearate pph 0.35 0.35 0.35 0.35
0.35 0.35 Additive F542 Phosphite stabilizer pph 0.06 0.06 0.06
0.06 0.06 0.06 Additive F6525 Cyasorb UV-3638 pph 0.095 0.095 0.095
0.095 0.095 0.095 Additive F527 Hindered phenol anti- pph 0.02 0.02
0.02 0.02 0.02 0.02 oxidant Diffuser R1540 Cross linked PMMA beads
pph 0.5 0.5 0 0 0 0 Diffuser R010722 Tospearl .TM. 120 pph 0.25
0.25 0.5 0.5 1 1 TSAN F449 SAN encapsulated PTFE pph 0 0.2 0 0.2 0
0.2 Typical Property Test Method Test Description Unit C2 E4 C3 E5
C4 E6 Luminous Integrating -- % 97.1 97.45 95.2 96.15 93 93.45
efficiency sphere Beam Angle Goniophotometer -- degree 147.0 154.6
182.1 214 219 223.7
[0068] It was observed that at different diffusion levels, TSAN
increases luminous efficiency and beam angle at the same time.
[0069] Table 5 presents an evaluation of flame retardant
properties.
TABLE-US-00005 TABLE 5 Item Item Code Item Description Unit C2 E7
E8 E9 E10 E11 PC 91982 THPE based branched PC pph 66 66 66 66 66 66
from high purity BAP2 PC 91761 High purity PC 175 pph 32.045 32.045
32.045 32.045 32.045 32.045 PC 91061 High Purity PC pph 1 1 1 1 1 1
Additive F4455 Potassium perfluorbutane, pph 0.08 0.08 0.08 0.08
0.08 0.08 sulfonate Additive F491 Octaphenylcyclotetrasiloxane pph
0.35 0.2 0.2 0.2 0.6 Additive F323340 Silicone oil (TSF437) pph 0
0.75 1.5 2.5 0.6 0.6 Additive F538 Pentaerythitrol tetrastearate
pph 0.35 0.2 0 0.2 0 0.2 Additive F542 Phosphate stabilizer pph
0.06 0.06 0.06 0.06 0.06 0.06 Additive F6525 Cytosorb .TM. UV-3638
pph 0.095 0.095 0.095 0.095 0.095 0.095 Additive F527 Hindered
phenol antioxidant pph 0.02 0.02 0.02 0.02 0.02 0.02 Diffuser
R010722 Tospearl 120 pph 2 2 2 2 2 2 TSAN F449 SAN encapsulated
PTFE pph 0 0.2 0.2 0.2 0.2 0.3 Typical Test Property Method Test
Description Unit C2 E7 E8 E9 E10 E11 Flame UL 94 UL 94 VO @ VO @ VO
@ VO @ VO @ VO @ VO @ Retardant 1.5 mm 0.75 mm 0.75 mm 0.75 mm 0.75
mm 0.75 mm 0.75 mm
[0070] It was observed that the combination of Silicone Oil,
octaphenylcyclotetrasiloxane and TSAN improves FR rating (e.g.,
improved from VO @ 1.5 mm to VO @ 0.75 mm).
Aspects
[0071] The present disclosure comprises at least the following
aspects.
[0072] Aspect 1. An optical component comprising a
polycarbonate-containing composition, the polycarbonate-containing
composition comprising:
[0073] about 95 wt % to about 99.6 wt % polycarbonate polymer;
[0074] about 0.25 wt % to about 1 wt % silicon resin,
[0075] about 0.05 wt % to about 0.5 wt % flame retardant, and
[0076] about 0.1 wt % to about 0.5 wt % styrene-acrylonitrile
copolymer coated polytetrafluoroethylene,
[0077] wherein the polycarbonate-containing composition exhibits a
VO rating at 0.75 mm as determined by the UL94 Flammability test;
and
[0078] wherein the total wt % of all components of the
polycarbonate-containing composition does not exceed 100 wt %.
[0079] Aspect 2. The optical component of Aspect 1, wherein at
least a portion of the polycarbonate is a branched
polycarbonate.
[0080] Aspect 3. The optical component of Aspect 2, wherein the
branched polycarbonate is produced from reagents comprising
bisphenol A and 1,1,1-tris-(4-hydroxyphenylethane).
[0081] Aspect 4. The optical component of any one of Aspects 1-3,
wherein the polycarbonate-containing composition comprises about 10
wt % to about 90 wt % branched polycarbonate.
[0082] Aspect 5. The optical component of any one of Aspects 1-4,
additionally comprising one or more of anti-oxidant, UV stabilizer,
and mold release agent.
[0083] Aspect 6. The optical component of any one of Aspects 1-5,
wherein the optical component is formed by injection molding.
[0084] Aspect 7. The optical component of any one of Aspects 1-6
wherein the polycarbonate-containing composition exhibits an
increased beam angle versus an analogous composition having no
styrene-acrylonitrile copolymer coated polytetrafluoroethylene.
[0085] Aspect 8. The optical component of any one of Aspects 1-7,
wherein the polycarbonate-containing composition exhibits increased
luminous efficiency versus an analogous composition having no
styrene-acrylonitrile copolymer coated polytetrafluoroethylene.
[0086] Aspect 9. The optical component of any one of Aspects 1-8,
wherein the flame retardant comprises at least one compound of the
formula
[(R).sub.2SiO].sub.y
wherein R is a monovalent hydrocarbon or fluorinated hydrocarbon
having from 1 to 18 carbon atoms and y is a number from 3 to
12.
[0087] Aspect 10. The optical component of any one of Aspects 1-9,
wherein the flame retardant is octaphenylcyclotetrasiloxane.
[0088] Aspect 11. The optical component of any one of Aspects 1-10
that is a LED lamp cover.
[0089] Aspect 12. The optical component of any one of claims 1-11,
additionally comprising one or more phosphors.
[0090] Aspect 13. A LED light comprising a LED lamp cover of Aspect
11.
[0091] Aspect 14. A polycarbonate-containing composition
comprising:
[0092] about 95 wt % to about 99.6 wt % polycarbonate polymer;
[0093] about 0.25 wt % to about 1 wt % silicon resin,
[0094] about 0.05 wt % to about 0.5 wt % flame retardant, and
[0095] about 0.1 wt % to about 0.5 wt % styrene-acrylonitrile
copolymer coated polytetrafluoroethylene,
[0096] wherein the total wt % of all components of the
polycarbonate-containing composition does not exceed 100 wt %
[0097] wherein the polycarbonate-containing composition exhibits a
VO rating at 0.75 mm as determined by the UL94 flammability test;
and
[0098] wherein the total wt % of all components of the
polycarbonate-containing composition does not exceed 100 wt %.
[0099] Aspect 15. The polycarbonate-containing composition of
Aspect 14, wherein at least a portion of the polycarbonate is a
branched polycarbonate.
[0100] Aspect 16. The polycarbonate-containing composition of
Aspect 14, wherein the branched polycarbonate is produced from
reagents comprising bisphenol A and
1,1,1-tris-(4-hydroxyphenylethane).
[0101] Aspect 17. The polycarbonate-containing composition of any
one of Aspects 14-16, wherein the polycarbonate-containing
composition comprises about 10 to about 90 wt % branched
polycarbonate.
[0102] Aspect 18. The polycarbonate-containing composition of any
one of Aspects 14-17, additionally comprising one or more of
anti-oxidant, UV stabilizer, and mold release agent.
[0103] Aspect 19. The polycarbonate-containing composition of any
one of Aspects 14-18, wherein the optical component is formed by
injection molding.
[0104] Aspect 20. The polycarbonate-containing composition of any
one of Aspects 14-19 wherein the polycarbonate-containing
composition exhibits an increased beam angle versus an analogous
composition having no styrene-acrylonitrile copolymer coated
polytetrafluoroethylene.
[0105] Aspect 21. The polycarbonate-containing composition of any
one of Aspects 14-20, wherein the polycarbonate-containing
composition exhibits increased luminous efficiency versus an
analogous composition having no styrene-acrylonitrile copolymer
coated polytetrafluoroethylene.
Definitions
[0106] It is to be understood that the terminology used herein is
for the purpose of describing particular aspects only and is not
intended to be limiting. As used in the specification and in the
claims, the term "comprising" can include the embodiments
"consisting of" and "consisting essentially of." Unless defined
otherwise, all technical and scientific terms used herein have the
same meaning as commonly understood by one of ordinary skill in the
art to which this disclosure belongs. In this specification and in
the claims which follow, reference will be made to a number of
terms which shall be defined herein.
[0107] As used in the specification and the appended claims, the
singular forms "a," "an" and "the" include plural equivalents
unless the context clearly dictates otherwise. Thus, for example,
reference to "a polycarbonate polymer" includes mixtures of two or
more polycarbonate polymers.
[0108] As used herein, the term "combination" is inclusive of
blends, mixtures, alloys, reaction products, and the like.
[0109] Ranges can be expressed herein as from one particular value
to another particular value. When such a range is expressed,
another aspect includes from the one particular value and/or to the
other particular value. Similarly, when values are expressed as
approximations, by use of the antecedent `about,` it will be
understood that the particular value forms another aspect. It will
be further understood that the endpoints of each of the ranges are
significant both in relation to the other endpoint, and
independently of the other endpoint. It is also understood that
there are a number of values disclosed herein, and that each value
is also herein disclosed as "about" that particular value in
addition to the value itself. For example, if the value "10" is
disclosed, then "about 10" is also disclosed. It is also understood
that each unit between two particular units are also disclosed. For
example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are
also disclosed.
[0110] As used herein, the terms "about" and "at or about" mean
that the amount or value in question can be the value designated
some other value approximately or about the same. It is generally
understood, as used herein, that it is the nominal value
indicated.+-.5% variation unless otherwise indicated or inferred.
The term is intended to convey that similar values promote
equivalent results or effects recited in the claims. That is, it is
understood that amounts, sizes, formulations, parameters, and other
quantities and characteristics are not and need not be exact, but
can be approximate and/or larger or smaller, as desired, reflecting
tolerances, conversion factors, rounding off, measurement error and
the like, and other factors known to those of skill in the art. In
general, an amount, size, formulation, parameter or other quantity
or characteristic is "about" or "approximate" whether or not
expressly stated to be such. It is understood that where "about" is
used before a quantitative value, the parameter also includes the
specific quantitative value itself, unless specifically stated
otherwise.
[0111] Disclosed are the components to be used to prepare the
compositions of the disclosure as hole as the compositions
themselves to be used within the methods disclosed herein. These
and other materials are disclosed herein, and it is understood that
when combinations, subsets, interactions, groups, etc. of these
materials are disclosed that while specific reference of each
various individual and collective combinations and permutation of
these compounds cannot be explicitly disclosed, each is
specifically contemplated and described herein. For example, if a
particular compound is disclosed and discussed and a number of
modifications that can be made to a number of molecules including
the compounds are discussed, specifically contemplated is each and
every combination and permutation of the compound and the
modifications that are possible unless specifically indicated to
the contrary. Thus, if a class of molecules A, B, and C are
disclosed as well as a class of molecules D, E, and F and an
example of a combination molecule, A-D is disclosed, then even if
each is not individually recited each is individually and
collectively contemplated meaning combinations, A-E, A-F, B-D, B-E,
B-F, C-D, C-E, and C-F are considered disclosed. Likewise, any
subset or combination of these is also disclosed. Thus, for
example, the sub-group of A-E, B-F, and C-E would be considered
disclosed. This concept applies to all aspects of this application
including, but not limited to, steps in methods of making and using
the compositions of the disclosure. Thus, if there are a variety of
additional steps that can be performed it is understood that each
of these additional steps can be performed with any specific aspect
or combination of aspects of the methods of the disclosure.
[0112] As used herein, the terms "weight average molecular weight"
or "Mw" can be used interchangeably, and are defined by the
formula:
M w = .SIGMA. N i M i 2 .SIGMA. N i M i , ##EQU00001##
where Mi is the molecular weight of a chain and Ni is the number of
chains of that molecular weight. Mw can be determined for polymers,
e.g. polycarbonate polymers, by methods well known to a person
having ordinary skill in the art using molecular weight standards,
e.g. polycarbonate standards or polystyrene standards, preferably
certified or traceable molecular weight standards.
[0113] The abbreviation "LED" means "light emitting diode".
[0114] An "analogous composition" is defined as being the same as
the referred to composition except as noted in the description.
[0115] "PC" is the abbreviation for polycarbonate.
[0116] "TSAN" is an abbreviation representing styrene/acrylonitrile
encapsulated polytetrafluoroethylene.
[0117] "TPHE" stands for tetrahydroxypropyl ethylenediamine. TPHE
can be used in the production of branched polycarbonates.
[0118] The abbreviation "mm" represents millimeters. When used in
terms of thickness, the measurement is at the thinnest portion of
the article.
[0119] "Wt %" (or "wt %") represents weight percent. Unless
otherwise specified, wt % is based on the total weight of the
composition.
[0120] "FR" stands for flame retardant.
[0121] "VO" represents the result of the UL 94 V-O test at a
certain thickness.
[0122] The abbreviation "g" represents gram or grams.
[0123] "Mol" is the abbreviation for mole or moles.
[0124] "pph" is the abbreviation for parts per hundred.
[0125] "cm.sup.2" is centimeters squared.
[0126] "mm" is the abbreviation for millimeter(s).
[0127] "s" is second(s).
[0128] ".degree. C." is degrees Celsius.
[0129] "kg" is kilogram(s).
[0130] "pbw" is parts per weight.
[0131] `hr" is hour(s).
[0132] "min" is minute(s).
[0133] "g" is gram(s).
[0134] "kgf/cm.sup.2" refers to a kilogram-force per square
centimeter.
* * * * *